Solar module mounting

ABSTRACT

Embodiments of the present disclosure are related to solar module mounting systems. A system may include an adhesion sheet configured to be secured to a roof of a structure via an adhesive. The system may further include at least one clamp configured for securing at least one solar module to the adhesion sheet. Other embodiments are related to methods of attaching one or more solar modules to a structure.

CROSS-REFERENCE TO RELATED APPLICATION

A claim for benefit of priority to the Sep. 14, 2015 filing date of theU.S. Patent Provisional Application No. 62/218,360, titled SOLAR MODULEMOUNTING SYSTEMS AND ASSOCIATED METHODS (the '360 Provisionalapplication), is hereby made pursuant to 35 U.S.C. § 119(e). The entiredisclosure of the '360 Provisional application is hereby incorporatedherein.

TECHNICAL FIELD

The present disclosure relates generally to solar module. Morespecifically, the present disclosure includes embodiments related tosecuring one or more solar modules to a structure.

BRIEF SUMMARY OF THE DISCLOSURE

According to one specific embodiment, a system may include one or moreadhesion sheets configured to be secured to a roof of a structure. Thesystem may also include at least one clamp configured for coupling tothe one or more adhesion sheets and securing at least one solar moduleto the one or more adhesion sheets. Another embodiment may include anadhesive and an adhesion sheet secured to a roof of a structure via theadhesive. The adhesion sheet may be configured to couple to at least onesolar module with an air-gap between the adhesion sheet and the at leastone solar module.

In another specific embodiment, a system includes at least one adhesionsheet configured to be secured to a roof of a structure. Further, thesystem includes at least one standoff configured for coupling the atleast one adhesion sheet to a solar module.

According to another embodiment, the present disclosure includes methodsfor mounting one or more solar modules to a structure (e.g., a roof of aresidential or commercial structure). Various embodiments of such amethod may include affixing one or more adhesion sheets to a roof of astructure. The method may also include coupling the one or more adhesionsheets to at least one solar module.

Other aspects, as well as features and advantages of various aspects, ofthe present disclosure will become apparent to those of skill in the artthough consideration of the ensuing description, the accompanyingdrawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a conventional solar module mounting system.

FIG. 2 depicts a solar module coupled to an adhesion sheet via aplurality of clamps, according to an embodiment of the presentdisclosure.

FIG. 3 depicts an array of solar modules coupled to a plurality ofadhesion sheets, according to an embodiment of the present disclosure.

FIG. 4 illustrates a solar module mounting system including an adhesive,an adhesion sheet, and a clamp, in accordance with an embodiment of thepresent disclosure.

FIG. 5 illustrates another solar module mounting system including anadhesive, an adhesion sheet, an attachment member, and a clamp, inaccordance with an embodiment of the present disclosure.

FIG. 6 illustrates another solar module mounting system including anadhesive, an adhesion sheet, and a clamp, according to an embodiment ofthe present disclosure.

FIG. 7 illustrates another solar module mounting system including anadhesive, an adhesion sheet, and a clamp, in accordance with anembodiment of the present disclosure.

FIG. 8 depicts another solar module mounting system comprising anadhesion sheet directly coupled to a frame of a solar module, inaccordance with an embodiment of the present disclosure.

FIG. 9 illustrates another solar module mounting system including anadhesive, an adhesion sheet, a racking rail, and a clamp, according toan embodiment of the present disclosure.

FIG. 10 depicts a cut string positioned on an adhesion sheet, accordingto an embodiment of the present disclosure.

FIG. 11 illustrates another solar module mounting system including anadhesive and an adhesion sheet, in accordance with an embodiment of thepresent disclosure.

FIG. 12 illustrates another solar module mounting system including aplurality of standoffs, according to an embodiment of the presentdisclosure.

FIG. 13 illustrates another solar module mounting system including aplurality of standoffs, according to an embodiment of the presentdisclosure.

FIG. 14 illustrates another solar module mounting system including aplurality of standoffs, in accordance with an embodiment of the presentdisclosure.

FIG. 15 illustrates another solar module mounting system including asnap-in tab, according to an embodiment of the present disclosure.

FIG. 16 depicts another solar module mounting system including arotation member, in accordance with an embodiment of the presentdisclosure.

FIGS. 17A and 17B depict solar module mounting systems including slotsfor receiving a solar module, according to an embodiment of the presentdisclosure.

FIG. 18 illustrates another solar module mounting system including anadhesive and an adhesion sheet, in accordance with an embodiment of thepresent disclosure.

FIG. 19 illustrates another solar module mounting system including anadhesive and an adhesion sheet, in accordance with an embodiment of thepresent disclosure.

FIG. 20 depicts a solar module mounting system including a skirt,according to an embodiment of the present disclosure.

FIG. 21 depicts a solar module mounting system including a ratchethold-down, in accordance with an embodiment of the present disclosure.

FIG. 22 illustrates another solar module mounting system including anadhesion sheet, according to an embodiment of the present disclosure.

FIG. 23 illustrates an example configuration of a solar module coupledto a plurality of adhesion sheets via a plurality of clamps, accordingto an embodiment of the present disclosure.

FIG. 24 illustrates another example configuration of a solar modulecoupled to a plurality of adhesion sheets via a plurality of clamps,according to an embodiment of the present disclosure.

FIG. 25 illustrates an example configuration of a plurality of solarmodules coupled to a plurality of adhesion sheets via a plurality ofclamps, in accordance with an embodiment of the present disclosure.

FIG. 26 depicts an example configuration of a plurality of adhesionsheets, according to an embodiment of the present disclosure.

FIG. 27 illustrates an embodiment including a plurality of solar modulescoupled to the adhesions sheets of FIG. 26.

FIG. 28 is a flowchart depicting a method, according to an embodiment ofthe present disclosure.

DETAILED DESCRIPTION

Referring in general to the accompanying drawings, various embodimentsof the present disclosure are illustrated to show the structure forsolar module mounting systems. Common elements of the illustratedembodiments are designated with like numerals. It should be understoodthat the figures presented are not meant to be illustrative of actualviews of any particular portion of the actual device structure, but aremerely schematic representations which are employed to more clearly andfully depict embodiments of the disclosure.

Solar photovoltaic (PV) cells use light energy (photons) from the sun togenerate electricity through a photovoltaic effect. A PV solar moduleincludes PV cells mounted behind glass and typically includes a frame atleast partially surrounding the edges of the cells and glass. Aframeless PV module typically does not include a frame. A glass-glass PVmodule, as known in the art, is a frameless module that uses glass onthe front and glass on the back of the module. A PV system, which mayinclude a plurality of solar modules and various other electricalcomponents, may be used to generate and supply electricity in utility,commercial and residential applications. Solar modules may also be ofthe type that converts energy from the sun into heat that is captured ina fluid running through collectors mounted behind glass. The heatedfluid may then be used, for example, to heat water for use in a home, apool, or a business. A solar hot water module typically includes a frameat least partially surrounding the edges of the glass and collectors.

One major cost of the solar industry is related to racking materials andlabor required to attach solar modules to a roof. In 2015, the averagecost of residential solar installations in the United States is about$4.93 per Watt. The cost of racking materials is approximately $0.25 perWatt. Further, according to the Rocky Mountain Institute, the averagetotal cost of the installation labor is $0.49 per Watt and the cost ofthe labor associated with racking and mounting is $0.16 per Watt. Thus,total costs associated with racking is approximately $0.41 per Watt. Itis desirable to reduce the cost of racking materials and associatedlabor.

In conventional PV solar mounting systems, such as mounting system 100illustrated in FIG. 1, holes are typically drilled through shingles, awaterproof roof membrane, and decking and into underlying rafters toattach the mounting system to a roof 106 of a structure 104 (e.g., ahouse) with a screw or a bolt 102. Further, lag bolts or screws are usedto hold the feet of the mounting system to the roof. Flashing andcaulking may be added to try to prevent roof leaks around the roofmembrane penetrations. However, any penetrations to a roof areundesirable, and flashing may fail or be improperly installed.Furthermore, it can be challenging to locate the rafters with a drilland often many holes are drilled before the rafter is found, thus makingthe flashing installation and patching more challenging. Roofpenetrations may worry some potential solar customers and prevent themfrom using solar energy because of the risk of leaks. Typical solarinstallation companies may see as much as 35% of all their customerrepair claims related to roof leaks, and the cost of repairing theseleaks can be millions of dollars per year. The steps of drilling,bolting, sealing and flashing are significant contributors to the laborand cost associated with installing a solar array.

In adhesive-based solar mounting systems, solar modules are attacheddirectly to shingles (e.g., composition or asphalt shingles) or tiles(e.g., clay or cement tiles) using an adhesive. These systems only workfor custom modules, and because a major surface of a solar module isadhered to a roof, heat of the module cells, which may reach 95 degreesCelsius in hot climates, may cause the adhesive to weaken or fail.Further, there is a minimal air-gap underneath a back sheet, thus, thesolar module may not receive as much convective cooling compared to amore traditional mounting system, which may include a larger air-gap. Aswill be understood, the efficiency of PV solar modules is typicallyreduced at higher cell temperatures, which is undesirable. Furthermore,because there is not a significant gap underneath the modules, ajunction box must be mounted on a top side of the solar module, thus,requiring some of the area that would have otherwise been filled withcells. This may reduce module efficiency and also may increase cost perwatt.

Various embodiments of the present disclosure may provide low cost, lowlabor systems and methods for attaching a variety of solar modules to astructure (e.g., a roof of a residential or commercial structure)without penetrating a waterproof membrane of the structure and whiletaking advantage of an air-gap between a surface of a solar module(i.e., a bottom surface when installed) and a surface of an adhesionsheet and maintaining the cost and efficiency of the solar module.

As described more fully below, an adhesion sheet may be attached to aroof (e.g., shingles or tiles of a roof) with an adhesive. The adhesionsheet may comprise any suitable material that may be adhered to the roofand also attached to one or more solar modules. For example, theadhesion sheet may comprise aluminum sheet metal having a thickness of,for example only, 0.125 inch. In one embodiment wherein the adhesionsheet is a conductive metal, the adhesion sheet may be configured toprovide electrical grounding to one or more solar modules (i.e., viaelectrical bonding). If the solar modules are frameless modules or havea non-conductive frame and do not require grounding, the adhesion sheetmay comprise a non-conductive material, such as a plastic, polymer,glass, or epoxy-based material. Solar modules with a conductive framecan also utilize a non-conductive (i.e., plastic, polymer, glass, epoxy,etc.) adhesion sheet but a method for grounding the conductive frames ofthe module (e.g., via a grounding wire) may be necessary. Conversely,frameless solar modules or modules with non-conductive frames mayutilize a conductive adhesion sheet. Further, the adhesion sheet mayinclude one or more inserts (e.g., threaded male or female inserts) orstandoffs (e.g., inserted standoffs, welded standoffs, integratedstandoffs, attached standoffs, etc.) configured to receive and/or coupleto one or more attachment devices (e.g., bolts, screws, nuts, or thelike) of one or more clamps, as described more fully below.

As will be understood, a roof may be warped, may have a bow, and/or mayhave a roll. The adhesion sheets described herein may be rigid, semirigid, or flexible and may be configured (e.g., with properrigidness/flexibility) to follow the contour of a roof (e.g., one thatis not a flat plane). Further, an adhesion sheet, which is suitablyflexible, may maintain surface area contact with the roof and contactwith the adhesive.

In various embodiments, a solar module frame may be coupled to anadhesion sheet via one or more clamps, which may include one or moreattachments devices configured for positioning in, or attaching to, oneor more inserts or standoffs of the adhesion sheet. Further, the clampsmay include one or more sharp points configured to “bite” into a solarmodule frame to provide bonding for electrical grounding between themodule frame and the adhesion sheet. Stated another way, a clamp may beconfigured to puncture a solar module frame and provide bonding forelectrical grounding between the module frame and the adhesion sheet.Further electrical bonding may be achieved via the threads or devicesthat connect the clamps to the adhesion sheet allowing a completeelectrical grounding path from the module frame to the adhesion sheet.The clamps may be suitable for a module with a frame or may be suitablefor a frame-less module, such as a glass-glass module.

The adhesive may be an adhesive suitable for adhering to both a roof(e.g., shingles or tiles) and the adhesion sheet. Non-limiting examplesof adhesives manufacturers that may have suitable adhesive productsinclude Royal Adhesives & Sealants of South Bend, Ind., Dow CorningCorporation of Midland, Mich., Sika Corporation of Lyndhurst, N.J., and3M of St. Paul, Minn.

FIG. 2 depicts a system 150 including a solar module 152 coupled to anadhesion sheet 156 via clamps 160. FIG. 3 depicts a solar module array155 including a plurality of adhesion sheets 156, a plurality of clamps160, and a plurality of solar modules 152.

FIG. 4 depicts a solar module mounting system 165, according to anembodiment of the present disclosure. Mounting system 165, which isconfigured to couple solar module 152 to a roof structure 154 (e.g., aroof of a residential or commercial structure), includes an adhesionsheet 156A and an adhesive 158. Roof structure 154 may include, forexample only, shingles 159. As will be appreciated, adhesion sheet 156Amay be affixed to a surface of roof structure (i.e., shingles 159) withadhesive 158. In this embodiment, adhesion sheet 156A may include aninsert 164, which may comprise, for example, a female threaded insert.In another example (not shown), insert 164 may comprise a male threadedinsert. Further, adhesion sheet 156A may be coupled to one or more solarmodules 152 with a clamp 160A. By way of example only, clamp 160A mayinclude an attachment device 162 (e.g., bolt, screw, etc.) configured tobe positioned within insert 164 of adhesion sheet 156A. In anotherexample, when the insert 164 is a male insert, attachment device 162 maybe a nut.

According to various embodiments, a solar module mounting system may beconfigured to adjust a height of one or more solar modules independentlyrelative to a plane of a roof. This may provide a leveling function toimprove aesthetics when a roof is not a substantially flat plane (e.g.,it is warped or bowed). The adjustment may be made via a clamp, anadhesion sheet, a standoff, an insert, or any combination thereof. Inone example, a threaded attachment device (e.g., a screw or bolt), whenrotated, may cause a solar module to either raise or lower relative tothe roof. In another example, one or more shims may be added under aframe of a solar module to raise the solar module.

With reference to FIG. 5, a solar module mounting system 170 may includean attachment member 180 configured to couple to a clamp 160B and anadhesion sheet 156B. Attachment member 180 may include an opening (e.g.,a slot) 186 through one portion 184 (i.e., one leg of attachment member180) and one or more openings (e.g., holes) on another portion 182(i.e., another leg of attachment member 180). The one or more holes mayallow for connection to adhesion sheet 156B (e.g., via one or moreattachment devices 162 into female inserts 164B of adhesion sheet 156Bor nuts onto male inserts (not shown)). When two or more holes are used,a weight of solar module 152 and/or lifting force from wind may bespread out on adhesion sheet 156B, which may comprise a thin material.Further, clamp 160B may be configured to couple to attachment member 180via an attachment device 163 (e.g., bolt, screw, etc.) that extendsthrough opening 186. It is noted that a position of solar module 152 andclamp 160B relative to adhesion sheet 156B is adjustable in thedirections indicated by arrows 188. More specifically, a position ofattachment device 163, which extends through opening 186 of portion 184,may be adjusted relative to adhesion sheet 156B in the directionsindicated by arrows 188. An air-gap 153, having a size that isadjustable, may exist between solar module 152 and adhesion sheet 156B.FIG. 6 depicts another solar module mounting system 190. In contrast tomounting system 170 (see FIG. 5) wherein attachment member 180 iscoupled to adhesion sheet 156B, an adhesion sheet 156C of solar modulemounting system 190 comprises an attachment member. For example only,when the adhesion sheet 156C is a sheet metal material, an attachmentmember may be a section of the sheet metal that has been bent up 90degrees to form vertical attachment member 180B.

It is noted that various clamps described herein may create a clampingforce (e.g., in a direction substantially perpendicular to the plane ofa glass portion of a solar module, in a direction substantially parallelto the plane of a glass portion of a solar module, or in a directionthat includes vector components in both directions) that secures thesolar module frame or glass (e.g., in a glass-glass module) to anadhesion sheet, clamp, rail, or standoff. In one embodiment, a solarmodule mounting system 200, as illustrated in FIG. 7, may include aclamp 160D configured to apply a clamping force (i.e., in a direction asindicated by arrows 194) that clamps module frame 191. Module frames mayinclude a flat portion that is perpendicular to the plane of moduleglass 192. A clamping force in a direction parallel to the plane of themodule glass may clamp this flat portion between an attachment member ofadhesion sheet 156D and clamp 160D, which is attached to adhesion sheet156D via an attachment device 162D. In another embodiment shown in FIG.8, a clamp is not required and module frame 191 is attached directly toan adhesion sheet 156D′ via attachment device 162D′. In this case,attachment device may comprise, for example, a self-tapping sheet metalscrew that threads into solar module mounting system 190. In thisembodiment, a grounding bond may occur via the threads of attachmentdevice 162D′ and solar module mounting system 190 and also between theadhesion sheet 156D′ and attachment device 162D′ (e.g., via a lockwasher, toothed lock washer, star washer, or biting teeth on the matingside of the screw head (not shown)). In another embodiment, clamp 160D(see FIG. 7) may be part of adhesion sheet 156D′. In the embodiments ofFIGS. 6-9, a position of solar module 152 relative to adhesion sheet 156may be adjusted in a direction perpendicular to arrows 194 andperpendicular to the plane of the module glass 192 or in the directionof arrows 188. Further, in some embodiments, clamp 160D may include agrounding bond.

FIG. 9 depicts another mounting system 220, according to an embodimentof the present disclosure. Mounting system 220 includes adhesion sheet156E, clamp 160E, and a racking rail 222, which may be configured tocouple to each of clamp 160E and adhesion sheet 156E. As illustrated,racking rail 222 may be coupled to adhesion sheet 156E via a bracket227, attachment device 229, an insert 226 (i.e., of adhesion sheet 156E;configured to receive attachment device 229), and attachment device 230.Insert 226 may be, for example, a female threaded insert, a malethreaded insert, or any other insert sufficient to attach adhesion sheet156E to bracket 227. Or bracket 227 may be part of adhesion sheet 156E.Attachment device 230 may extend through opening 228 (e.g., a slot) ofbracket 227 to couple bracket 227 to racking rail 222. As will beappreciated, a position of attachment device 230 within opening 228 maybe adjusted to adjust a position of racking rail 222 and solar module152 relative to adhesion sheet 156E, thus, adjusting a size of air-gap153. Further, clamp 160E may solar couple module 152 to racking rail 222via attachment device 162 and insert 232, which may be part of rackingrail 222 or may be a separate device that is captured inside rackingrail 222. This embodiment may allow the use of standard “off the shelf”racking components for some pieces of mounting system 220, potentiallyallowing for electrical bonding, adjustability (e.g., in a directionperpendicular to a surface of a roof), wire management, and skirtaccessories of a standard racking system.

As will be understood by a person having ordinary skill in the art, PVsolar systems are sometimes financed by third parties. Thus, it isimportant that PV equipment does not become a “fixture” of a structure(e.g., house), so that the financing party can maintain ownership andlien rights to the PV equipment. Solar modules that are directly adheredto a roof of a structure may be considered a fixture by some entities.Various embodiments described herein may eliminate this issue becausemodules may attach to an adhesion sheet in the same way they attach to atraditional racking system (e.g., with removable clamps, screws, orother fasteners). Hence, the concern around non-fixtured PV equipmentmay be avoided.

As will be appreciated, one or more solar modules of the systemsdescribed herein may be removed by removing one or more clamps, screws,or other fasteners. Further, an adhesion sheet may be removed by, forexample, heating an adhesive to a high temperature with, for example, aheating blanket. When the adhesive reaches a certain temperature (e.g.,100 degrees Celsius), the adhesive may become soft and may release whenthe adhesion sheet is lifted.

Another embodiment illustrated in FIG. 10 includes an adhesive cutstring 242. In one example, one end 246 of cut string 242 may be securedto a portion (e.g., a bottom side corner) of an adhesion sheet 156F(e.g., with a rivet or screw). Cut string 242 may then be routed arounda perimeter of a side of adhesion sheet 156F encircling adhesive 158.Cut string 242 may be temporarily held in place (e.g., with tape) whileadhesive 158 is applied. On another end 248, cut string 242 may includea pull loop or pull ring 250. After adhesion sheet 156F is adhered to aroof, pulling on ring 250 may cause cut string 242 to cut throughadhesive 158, thus, separating adhesion sheet 156F from the roof.Adhesive cut string 242 may comprise, for example only, a suitablystrong thin piece of metal, wire, cable, carbon fiber, or other materialthat when pulled may cut through adhesive 158 (e.g., like a string usedto cut clay or cheese, or like a cable saw).

FIG. 11 depicts another embodiment of a solar module mounting system260. Solar module mounting system 260 includes an adhesion sheet 156G,which, in this embodiment, may comprise sheet metal having a thicknessof, for example only, substantially 0.0313 inch. Further, adhesion sheet156G may be fastened directly to module frame 191 with, for example,screws or rivets 262.

In another embodiment, a solar module may be coupled to an adhesionsheet with an adhesive and without clamps. If the solar module is aframed module, a bottom surface of the frame may be adhered to a topsurface of the adhesion sheet. If the module is a frameless module, abottom portion of the module (e.g., back sheet or back glass (i.e., in aglass-glass module)) may be adhered to a top surface of the adhesionsheet. When the adhesion sheet is in contact with the module (e.g., theback sheet or back glass), the adhesion sheet may act as a heat sinkthat may draw heat away from the module cells. This may improve theconversion efficiency of the modules by lowering their operatingtemperature.

As non-limiting examples, adhesives that may provide adequate adhesionbetween a solar module and the adhesion sheet include silicon (PV-8301,PV-8303, and PV-8030) from Dow Corning Corporation, silicon (AS-785 andAS-70) from Sika Corporation, and solar acrylic foam tape from 3M.

In another embodiment, a solar module may be adhered to a surface of aroof without an adhesion sheet. If the module is a framed module, abottom surface of the frame may be adhered to a top surface of the roof(e.g., the shingles or tiles). If the module is a frameless module, aback sheet or back glass (i.e., in a glass-glass module) may be adheredto a top surface of the roof. A heating blanket and/or a cut string maybe used for removing a solar module from a roof surface, if needed.

In various embodiments, one or more standoffs may be positioned betweenan adhesion sheet and a solar module. FIGS. 12 and 13 respectivelyillustrate solar module mounting systems 280 and 300, each of whichincluding standoffs 282. A standoff may be adhered or attached to aportion (e.g., a top side) of an adhesion sheet, or may be part of anadhesion sheet, as shown in FIGS. 12 and 13. Further, a surface (e.g., atop surface) of standoffs 282 may be adhered to a portion (e.g., aframe, back sheet or bottom glass) of solar module 152. In one example,standoffs may be ridges that run the length or width of a solar module.In another example, standoffs may be posts or pillars that are circular,oval, or rectangular and only contact a limited internal area of theback of the module (e.g., standoffs do not run the length or width of amodule). Positioning one or more standoffs internal to the area of solarmodule 152, rather than the traditional location of supports and clamps(i.e., along the edges of a solar module), may optimally distribute theweight of solar module 152 and any loading on solar module 152. This mayreduce the cost of solar module 152 by allowing the module glass to bethinner due to the narrower span or eliminating the need for frames in astandard single glass module. An adhesion sheet (e.g., adhesion sheet156H of FIG. 12 or adhesion sheet 156I of FIG. 13) may extend beyond theperipheral edges of solar module 152 to provide some protection whenhandling (e.g., when adhesion sheet is attached to module prior tohandling), or adhesion sheet 156 may be smaller than the dimensions ofsolar module 152.

In one embodiment of a solar module array that does not include edgeclamps, solar modules may be installed edge-to-edge without any gapbetween adjacent modules, thus, enhancing the aesthetics and improvingthe use of roof space (typically edge clamps require an approximately0.5 to 1 inch gap between modules, thus, for example, a row of fivemodules, may need an extra 2.5 to 5 inches of run). In anotherembodiment, when bifacial solar modules (e.g., modules that generateenergy from sunlight impinging on the bottom as well as the top surfaceof the module) are used, a surface of an adhesion sheet (i.e., a surfacefacing a solar module) may be reflective to maximize an amount ofsunlight that is reflected back to an underside of the solar module.

As will be appreciated, PV modules that use a glass layer may not bevery flexible, whereas roofs may be warped or bowed. However, there maybe a need to maintain surface area contact between an adhesion sheet andthe roof. In one embodiment, adhesion sheet 156I (see FIG. 13) may besuitably flexible to follow a shape of a surface of a roof 154″. In thiscase, standoffs 282B may also be flexible (e.g., made of a flexiblematerial such as plastic or polymer) or articulated (e.g., have a hingeor joint such as a ball joint). This may allow adhesion sheet 156I tomaintain surface area contact with the roof and adhesive 158 while alsoallowing standoffs 282B to maintain surface area contact with asubstantially flat surface of solar module 152 and adhesive 158, asshown in FIG. 13.

In another embodiment, the standoffs may include a height adjustmentdevice. In this embodiment, for example, one or more standoffs mayinclude a threaded member that when rotated (e.g., with a wrench) adjusta position (e.g., height) of a solar module relative to a surface of theroof. This may be useful when leveling one or more solar modules or whenthe surface of the roof is not flat.

In another embodiment illustrated in FIG. 14, a solar module mountingsystem 320 may include standoffs 322, which may provide protection tosolar module 152. More specifically, for example, standoffs 322 may helpprevent damage to corners or edges of solar module 152, especially ifsolar module 152 is a frameless module. In addition, if air-gap 153beneath the module is relatively large, wind loading in strong winds cancreate upwards pressure, which tends to pull solar module 152 fromadhesion sheet 156J, or adhesion sheet 156J can lose adhesion to theroof. The standoffs 322 can act as wind deflectors to keep the wind outof air-gap 153 beneath the module, reducing the wind pressure. Thisembodiment may allow a solar module to be coupled to adhesion sheet 156Jand standoffs 322 at a warehouse or factory, so the solar module is lesslikely to be damaged in transportation and/or handling, especially whilebeing hoisted onto a roof. In the embodiment of FIG. 14, solar module152 may be adhered to standoffs 322. In another embodiment, a solarmodule mounting system may include mechanical clamps that couple to(e.g., screw into) standoffs 322 and secure a solar module. Thestandoffs may support and protect only a portion of the module edges(e.g., 2 to 4 inches in four locations around the perimeter of themodule) or they may support and protect all of the module edges (e.g.,the entire perimeter of the module).

In another embodiment, a standoff, an adhesion sheet, a clamp, or anycombination thereof, may include one or more snap-in tabs, which mayallow for a solar module to be quickly secured, possibly without tools(e.g., a wrench). In one example, as depicted in solar module mountingsystem 340 of FIG. 15, a portion (e.g., an edge) 151 of solar module 152may be inserted under a substantially non-bending catch 343. Catch 343may be coupled to, or may be part of, standoffs 346, adhesion sheet156K, a clamp (not shown in FIG. 15), or any combination thereof.Another portion (e.g., another edge) 157 of solar module 152 may bepositioned onto a snap-in tab 342, which is configured to bend (i.e.,out of the way of solar module 152) as solar module 152 is pressed down.Snap-in tab 342 may then snap back to its default position (asillustrated) to secure solar module 152 when solar module 152 is fullyseated. A compliant material 344, such as foam weather stripping orrubber, may be included between a supporting area 348 and solar module152 to provide a spring force, if needed.

In another embodiment shown in FIG. 16, one or more clamps 350 maycomprise rotation members (e.g., quarter-rotation members) configured tobe attached to one or more standoffs and/or an adhesion sheet via apivot, such as a screw. When rotated (e.g., a quarter turn (i.e., 90degrees), as depicted by reference numeral 352), one or more clamps 350may secure the solar module (e.g., clamp the solar module in place). Inthis embodiment, the one or more clamps may be pre-integrated withstandoffs or an adhesion sheet. The rotation members may be used alongone or more edges of the module.

In another embodiment shown in FIGS. 17A and 17B, solar module 152 maybe positioned (e.g., slid into—in a direction depicted by arrow 354) ina slot contained in standoffs or adhesion sheet (e.g., adhesion sheet156N of FIG. 17A and FIG. 17B). The solar module 152 may be capturedalong three edges and an upper surface of the glass is open to sunlight(except for a narrow ridge capturing the module). The fourth edge may besecured with a fastener or latch (not shown). In one example, when theslide-in feature is part of the adhesion sheet, the adhesion sheet maybe molded of plastic or rubber. The adhesion sheet may function as abumper for the module providing protection when handling (e.g., ifattached prior to handling) and may also provide the surface foradhesion to a roof. Removing the module later simply requires removingany fastener or latch and sliding the module out.

In another embodiment when the full area of an adhesion sheet is notneeded to reliably adhere to the roof and provide sufficient structuralsupport, the adhesion sheet may be a non-flat surface. For example, asillustrated in FIG. 18, a solar module mounting system 360 may includean adhesion sheet 156L including a corrugated surface. This embodimentmay reduce costs (i.e., of an adhesion sheet) while still providingadequate adhesion surface and while improving the heat-sinking propertyof the adhesion sheet, pulling more heat from the cells. It will bereadily apparent to one of ordinary skill in the art that the non-flatadhesion sheet may be corrugated, “square-wave” shape, “triangular-wave”shape, or any other shape that provides contact and heat-sinking to theback of the module.

FIG. 19 depicts another embodiment of the present disclosure wherein asolar module mounting system 380 includes an adhesion sheet, which mayinclude both a substantially flat portion 156M for an adhesion area anda non-flat (e.g., corrugated) portion 156M′ configured to function as aheat sink.

In another embodiment, one or more clamps may attach to an adhesionsheet by sliding into slots stamped or cut in the adhesion sheet.Alternatively, attachment points may be adhered or welded to theadhesion sheet. This may reduce the cost of the adhesion sheet and/orclamps.

According to another embodiment, a skirt may be attached to an adhesionsheet or one or more clamps or standoffs. The skirt may provide enhancedaesthetics, for example, by hiding a lower edge of a solar array from anoff the roof view, or it may provide wind deflection, or it may providewire management. In general, the larger the air-gap or the distancebetween the adhesion sheet and the modules, the larger the upward windloading may be under high winds. One or more skirts around the module orarray may deflect the wind reducing the upward wind loading. Typically,each module has two wires coming off it and the modules are typicallyconnected in series. It is desirable to minimize the amount of movementthe wires may experience from wind to minimize abrasion and thelikelihood of wearing away some of the insulation. The skirt may enablefor managing the wires by keeping them neat, contained, hidden fromview, and prevent movement in the wind. In one embodiment, the skirt maybe part of the adhesion sheet. For example, an adhesion sheet 156Q maybe folded up along one or more edges (e.g., a bottom edge) to create askirt 382 as shown in FIG. 20.

In another embodiment shown in FIG. 21, one or more clamps may comprisea ratchet hold-down 384 (e.g., zip ties or the like) that secure a solarmodule to one or more standoffs, clamps, or an adhesion sheet (e.g.,adhesion sheet 156R) when secured (e.g., by an installer). The ratchethold-down may comprise one-way flexible tabs or ridges that allow motionin one direction (e.g., as shown by arrow 386 in FIG. 21) but not in theopposite direction. Ratchet hold-down 384 may include a device 388(e.g., a wedge-shaped piece of material) at one end that secures themodule edge by pushing it down and/or toward the center of the adhesionsheet. An advantage of this embodiment may be that no tools (e.g., awrench) is required to attach the module. The ratchet hold-downs may bemade of a UV resistant plastic, metal, or any other suitable material.The one-way flexible tabs may be part of the ratchet hold-downs asshown, or may be part of the standoffs or adhesion sheet with ridges onthe ratchet hold-downs that catch the tabs.

It is noted that by using frameless modules, adhesives, andnon-conducting materials for the racking, all metal may be eliminatedfrom a solar module mounting system, which may eliminate the need forgrounding wires on a roof, thus, reducing cost and time for electricalwork.

In another embodiment, an adhesion sheet may include one or more wirerouting trays for PV wires between solar modules that protect and hidethe wiring. A typical residential system includes one or two junctionboxes where strings are combined on a roof and the PV wiring transitionsto conduit wiring. In one embodiment of the present disclosure, wiremanagement is included in the system. For example, the adhesion sheetmay include loops or tabs where wires may be secured. In anotherexample, one or more wiring junction boxes may be integrated with anadhesion sheet, or the adhesion sheet may include attachment points forone or more junction boxes and/or conduit.

According to another embodiment, an adhesion sheet may comprise a frameconfigured to support a solar module and provide cavities for anadhesive to adhere to a roof and an underside of the solar module. Forexample, with reference to FIG. 22, a solar module mounting system 400includes adhesion sheet 156N and cavities 402, which, in thisnon-limiting embodiment, are triangular shaped. An adhesive may beapplied to cavities 402. By way of example only, a foam adhesive mayfill the volume of cavities 402. Dashed line 404 represents a solarmodule footprint.

In another embodiment, an adhesion sheet may include one or moreadhesive injection ports 410 (e.g., see FIGS. 4 and 6). The injectionports 410 may be analogous to automotive lubrication ports that a greasegun may be mated with for injecting lubricant into moving parts, such asshaft bearings. The adhesive injection ports 410 may be mated with anadhesive injector that may include a pump and an adhesive supply. Whenenabled, the adhesive may be injected into the injection ports 410,which may guide the adhesive to different locations between the adhesionsheet and a roof. This may assure that an adequate amount of adhesive isused (e.g., the adhesive injector may include a means of measuring thevolume of adhesive injected). For example, the adhesive may be appliedto an entire adhesion sheet via a single adhesive port. This may enablethe use of a more fluid adhesive (e.g., as compared to adhesive pads). Amore fluid adhesive may fill gaps better providing better adhesion tothe roof. When the adhesive cures it may become less fluid. Examples offluid roof adhesives are Extreme WET PATCH® and Cold-Ap Roof and LapAdhesive, each of which made by Henry Company of El Segundo, Calif. Inanother embodiment, the adhesive may comprise a foam material that mayfill the gaps and volume. In another embodiment, the adhesive maycomprise one or more peel-and-stick pad(s). Further, the adhesive may beapplied to the roof, the adhesion sheet, or both, with an applicatorsuch as a caulking gun, brush, or pressurized canister.

It is noted that the adhesion sheet and/or standoffs described herein,may be molded. For example, the adhesion sheet and/or standoffs may beinjection molded, vacuum molded, or molded in any other fashion. Inanother embodiment, the adhesion sheet and/or standoffs may be milled orcut. The adhesion sheet and/or standoffs may be plastic, polymer, carbonfiber, fiberglass, metal, etc. In yet another embodiment, the adhesionsheet and/or standoffs may be fabricated with a form. For example, ifthe material is fiberglass or carbon fiber, a form may be created (e.g.,from wood or metal) and one or more layers of material may be appliedwith a resin or epoxy to form the shape. Alternatively, the adhesionsheet and/or standoffs may be 3D printed with, for example, anextrusion, light polymerized, powder bed, laminated, wire technique,additive manufacturing, stereo lithography (SLA), resin printing,selective laser sintering (SLS), or any other 3D printing techniques.Alternatively, the adhesion sheet and/or standoffs may be extruded.

In many of the embodiments disclosed herein, the adhesion sheets shownare approximately 90% to 110% of the area of the solar modules. Inanother example, the area of the adhesion sheets may be more or less,for example, 50% of the area of the solar module. In general, the areaof the adhesion sheet may be sufficiently large to secure a solar moduleto a roof under extreme wind and environmental conditions. The requiredarea may depend on the holding properties of the adhesive and thestructural capabilities of the shingles or tiles and their attachment tothe decking. When a framed module is clamped onto a flat adhesion sheet,the adhesion sheet may be smaller than the openings on a back side ofthe module (e.g., an inch or two smaller than the outer dimensions ofthe module) in one dimension (length or width) so that there may be agap between the bottom of the module frame and the roof in which the PVwires may be routed. Furthermore, for aesthetics, the amount that theadhesion sheets extend past the edges of the modules may be minimized.

In various embodiments disclosed herein, four clamps are attached to anadhesion sheet. In other embodiments, less than four clamps 160 (e.g.,one, two, or three) may attach to one adhesion sheet as shown in FIGS.23 and 24. Moreover, in other embodiments, more than four clamps may beattached to an adhesion sheet.

As illustrated in the example shown in FIG. 25, an adhesion sheet mayspan multiple solar modules, which may reduce the number of parts andsimplify the alignment of the solar modules. This may reduce the spacingbetween the modules slightly when there is a clamp in between themodules.

With reference to FIG. 26, in another embodiment, adhesion sheets 156Tmay be interlaced to minimize the spacing between solar modules 152 whenthere are one or more clamps between solar modules 152 shown in FIG. 27.Clamps 160 positioned between solar modules 152 may be double clampsconfigured to support both modules with a single clamp.

In other embodiments, when the area of one or more adhesion sheets issmall relative to the area of one or more solar modules, a mountingsystem may include a relatively small number of roof penetrations intothe rafters or decking. In these embodiments, a number of roofpenetrations may be much smaller than in a traditional mounting systembecause the adhesive provides some of the structural attachment strengthso fewer penetrations may be needed. Further, the penetrations may beinto the decking (e.g., plywood) as opposed to the rafters, as isusually required for conventional mounting systems. For example,screwing into the decking, as opposed to the rafters, may simplify theprocess of securing roof penetrations because locating the rafters canbe challenging. In one embodiment of the present disclosure, theadhesion sheets may be attached to a roof with adhesive and at variousportions (e.g., at a top and a bottom) with one or more attachmentdevices (e.g., lag bolts) secured to the decking. The attachment devicesmay then be covered with flashing.

FIG. 28 is a flowchart illustrating a method 500, in accordance with oneor more embodiments. Method 500 may include affixing one or moreadhesion sheets to a roof of a structure (depicted by numeral 502).Method 500 may also include coupling the one or more adhesion sheets toat least one solar module (depicted by numeral 504).

As described herein, the present disclosure includes various solarmodule mounting systems, which may include an adhesion sheet that may beadhered to a surface of a roof. Various embodiments do not requirepenetration of a roof's waterproof membrane, thus, reducing thelikelihood of leaks and saving significant cost and time. An adhesionsheet may be attached directly to one or more modules with, for example,an adhesive, clamps, clamps plus supporting cross pieces such as rackingrails (“rails”), snap-in tab(s), standoffs, ratchet hold-downs,quarter-turn member(s), slide-in slots, or any combination thereof. As asolar module is mounted a greater distance from a surface of a roof(e.g., resulting in a greater air-gap), wind loading requirements of theadhesive and adhesion sheet may increase, possibly requiring a largeradhesion sheet area, more adhesive, other securing means (e.g., roofpenetrations), one or more skirts, or any combination thereof.

The previous description of the disclosed embodiments is provided toenable any person skilled in the art to make or use the presentdisclosure. Various modifications to these embodiments will be readilyapparent to those skilled in the art, and the generic principles definedherein may be applied to other embodiments without departing from thespirit or scope of the disclosure. Thus, the present disclosure is notintended to be limited to the embodiments shown herein but is to beaccorded the widest scope consistent with the principles and novelfeatures disclosed herein.

What is claimed is:
 1. A solar module mounting system, comprising: oneor more adhesion sheets configured to be secured to a roof of astructure via an adhesive and without penetrating the roof, the one ormore adhesion sheets including at least one of a metal sheet, a carbonfiber sheet, a glass sheet, and an epoxy-based material sheet, the oneor more adhesion sheets further including at least one insert configuredto be positioned adjacent the roof and to receive at least one of a boltand a screw; and at least one clamp configured for securing at least onesolar module and coupling directly to the one or more adhesion sheetsvia the insert and the at least one of the bolt and the screw withoutpenetrating the roof, the one or more adhesion sheets and the at leastone clamp configured such that a bottom surface of a frame of the atleast one solar module contacts an upper surface of the one or moreadhesion sheets, the at least one clamp configured to apply a force in adirection substantially parallel to a plane of glass of the at least onesolar module; the one or more adhesion sheets having at least one of alength and a width substantially equal to or greater than an associateddimension of the at least one solar module.
 2. The solar module mountingsystem of claim 1, further comprising a cut string coupled to the one ormore adhesion sheets and configured to cut through a portion of theadhesive on the one or more adhesion sheets.
 3. The solar modulemounting system of claim 1, wherein the at least one clamp comprises asnap-in tab.
 4. The solar module mounting system of claim 1, furthercomprising the at least one solar module secured to the one or moreadhesion sheets, wherein a surface of the one or more adhesion sheetsfacing the at least one solar module comprises a reflective surface. 5.The solar module mounting system of claim 1, further comprising anattachment member coupled to each of the at least one clamp and the oneor more adhesion sheets via a plurality of attachment devices, theattachment member including a first member extending in a first planeand a second member extending in a second plane, substantiallyperpendicular to the first plane.
 6. The solar module mounting system ofclaim 1, wherein at least one adhesion sheet of the one or moreadhesions sheets has an area of at least approximately 90% of an area ofthe at least one solar module.